Ducting assembly for de-stratification and consolidating excess water and nutrients

ABSTRACT

A tray system for use in horticultural or agricultural operations comprising a ducting assembly for de-stratification and a drainage system for consolidating excess water and nutrients.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.17/200,330, filed Mar. 12, 2021, which claims priority to U.S.Provisional Application No. 63/061,106, filed Aug. 4, 2020, thedisclosure of which are incorporated herein by reference in itsentirety.

TECHNOLOGICAL FIELD

This disclosure relates to a tray system for use in horticultural oragricultural operations.

BACKGROUND

Air stratification and excess water/nutrient collection are two problemsassociated with enclosed vertical agricultural operations. Airstratification can occur when insufficient ventilation is present, andcan be especially problematic for the lower levels of racked operationswhere the canopy of one level of crop tends to prevent the downwardcirculation of air from vents or fans, which are typically present onthe ceiling. Stratification is the layering of air due to densityvariations caused by temperature, humidity, carbon dioxide depletionetc. and is detrimental to the health of the crops being grown.

Enclosed vertical agricultural operations require that the rackingsystems provide a method of collecting and consolidating excess waterand nutrients draining from the individual growing containers. Fluidthat is not consolidated and removed from the operation can foster thegrowth of mold, fungus and other organisms detrimental to the health ofthe crops.

Current conventional solutions depend on a combination of technologiesto implement drainage and de-stratification using separate trays andcombinations of duct work and fans mounted below the growing trays,interfering with the positioning of lighting and potentially decreasingpossible vertical density.

SUMMARY OF THE DISCLOSED SUBJECT MATTER

To address the problems in the prior art, a tray system for plantcultivation is provided.

In one aspect, disclosed is tray system for plant cultivation comprisinga tray comprising opposed end walls and opposed side walls defining aperimeter of the tray; and a raised region disposed within the perimeterof the tray; a duct assembly comprising one or more air passages

having opposed open ends proximate to the end walls of the tray and aplurality of orifices in the one or more air passages to distribute airout of the one or more air passages; wherein the end walls of the trayeach comprise an opening configured to provide access to one of the openends of the duct assembly and the side walls of the tray extend belowthe raised region to hold the raised region above the duct assembly.

Embodiments of the tray system include any of the following embodimentsor any other embodiments disclosed herein, alone or in any combination.

The tray system, wherein the raised region comprises a plurality ofridges disposed between the side walls and parallel to the end walls anda plurality of valleys formed between adjacent ridges of the pluralityof ridges wherein the valleys are in fluid communication with a gutter;and optionally a plurality of holes in a subset of the ridges.

The tray system, wherein the plurality of alternating parallel ridgescomprise top surfaces defining a level plane for supporting one or moreindividual growing containers for containing growth medium and plants,and the valleys slope downward from a peak aligned with a center of thetray to a gutter proximate to the perimeter of the upper tray, whereinthe valleys are in fluid communication with the gutter for channelingfluid collected in the valleys into the gutter.

The tray system, wherein a set of the plurality of alternating parallelridges comprises a central boss.

The tray system, wherein the gutter is configured to be in fluidcommunication with a fluid drainage system.

The tray system wherein the duct assembly comprises a first open endconfigured to be in fluid communication with a ventilation system and asecond open end opposed to the first open end configured to beoptionally closed or optionally in fluid communication with a secondduct assembly.

The tray system wherein the duct assembly comprises one or more toppanels; one or more bottom panels; a first elongate side support memberand a second elongate side support member, each configuredperpendicularly to the ridges of the tray and engaged to the one or moretop panels and the one or more bottom panels; and optionally one or moreelongate center support members configured perpendicularly to the ridgesof the tray and engaged with the one or more top panels and the one ormore bottom panels, wherein the first and second side support members,the one or more top panels, the one or more bottom panels, and theoptional one or more center support members define one or more ductshaving open ends proximate to the end walls of the tray.

The tray system wherein the duct assembly comprises a plurality of holesin the one or more top panels configured to be in fluid communicationwith a plurality of holes in raised region of the tray to direct airfrom the duct assembly to above the tray; or a plurality of holes in theone or more bottom panels configured to direct air from the ductassembly to below the duct assembly; or a plurality of holes in the oneor more top panels configured to be in fluid communication with aplurality of holes in raised region of the tray to direct air from theduct assembly to above the tray and a plurality of holes in the one ormore bottom panels configured to direct air from the duct assembly tobelow the duct assembly.

The tray system wherein the duct assembly comprises a plurality of holesin the one or more top panels configured to be in fluid communicationwith the plurality of holes in raised region of the tray to direct airfrom the duct assembly to above the tray.

The tray system wherein the duct assembly comprises a plurality of holesin the one or more bottom panels configured to direct air from the ductassembly to below the duct assembly.

The tray system wherein the duct assembly comprises a plurality of holesin the one or more top panels configured to be in fluid communicationwith the optional holes in the subset of ridges of the tray to directair from the duct assembly to above the tray and a plurality of holes inthe one or more bottom panels configured to direct air from the ductassembly to below the duct assembly.

The tray system further comprising a duct member disposed above the traycomprising a hollow elongate member defining a lumen and a plurality ofopenings in the hollow elongate member wherein the lumen and theplurality of openings are in fluid communication with the plurality ofholes in the raised region of the tray and the plurality of holes in theone or more top panels of the duct assembly to direct air from the ductassembly to above the tray.

The tray system wherein the duct member disposed above the tray isdisposed parallel to the end walls of the tray.

The tray system wherein the duct member disposed above the tray isdisposed perpendicular to the end walls of the tray.

The tray system wherein the duct assembly comprises a first elongateside support member and a second elongate side support member eachextending between the ends of the tray system, each having across-section comprising a top section configured to support a bottomsurface of the tray below the valleys proximate to the side walls of thetray and engage a top panel of the duct assembly, and a bottom sectionconfigured to engage a bottom panel of the duct assembly; and a centerelongate support member having a cross-section comprising a top sectionconfigured to support a bottom surface of the tray below the valleysproximate to the side walls of the tray and engage a first top panel ona first side and engage a second top panel on a second side and a bottomsection configured to engage a first bottom panel on the first side anda second bottom panel; wherein the first elongate side support member,the first side of the center support member, the first top panel and thefirst bottom panel define a first duct in the duct assembly configuredto nest below the valleys of the tray in a first region of the traybetween the first side support member, and the center support member andthe second elongate side support member, the second side of the centersupport member, the second top panel and the second bottom panel definea second duct in the duct assembly configured to nest below the valleysof the tray in a second region of the tray between the second sidesupport member and the center support member.

The tray system, wherein the central support member has a cross-sectioncomprising a top section configured to support the bottom of the peak ofeach of the valleys of the tray, a middle section comprising a bar, anda bottom section configured with a first shelf extending from a firstside of the middle bar section, and a second shelf extending from asecond side of the middle bar section.

The tray system, wherein the first and second elongate side supportmembers each comprise a top section configured to support the bottom ofeach of the valleys of the tray proximate to the sides of the tray and ashelf to engage a top panel of the duct assembly, and a bottom sectioncomprising a shelf extending toward the central support memberconfigured to engage a bottom panel of the duct assembly.

The tray system, further comprising a first tray system and a secondtray system, wherein ends of the first and second tray system areconnected to each other to provide an integrated system of a pluralityof tray systems.

The tray system, wherein duct assembly and the tray are configured torest on a rack system.

The tray system, comprising a tray comprising opposite end walls andopposite side walls; a plurality of ridges extending between the sidewalls and the end walls; a plurality of valleys formed between adjacentridges of the plurality of ridges in fluid communication with a gutter;and optionally a plurality of holes in a subset of the ridges; a ductassembly comprising an elongate central support member configuredperpendicularly to the ridges extending between the ends of the traysystem; a first and a second elongate side support member extendingbetween the ends of the tray system each having a cross-sectioncomprising a top section configured to support a bottom surface of thetray below the valleys; and a first elongate hollow duct memberconfigured to nest below the valleys of the tray in a first region ofthe tray between the first side support member and the center supportmember and a second elongate hollow duct member configured to nest belowthe valleys of the tray in a second region of the upper tray between thesecond side support member and the center support member, wherein endsof the first and second duct members are configured to fluidlycommunicate with a ventilation system; top surfaces of the first andsecond duct members optionally comprise a plurality of orifices in fluidcommunication with the optional plurality of holes in the subset ofridges of the tray to provide air flow out of the first and second ductmembers above the tray system; and bottom surfaces of the first andsecond duct members optionally comprise a plurality of orifices toprovide air flow out of the first and second duct members below the traysystem.

The tray system wherein the plurality of alternating parallel ridgescomprise top surfaces defining a level plane for supporting one or moreindividual growing containers for containing growth medium and plants,and the valleys slope downward from a peak aligned with center of thetray to a gutter adjacent to the perimeter of the upper tray, whereinthe valleys are in fluid communication with the gutter for channelingfluid collected in the valleys into the gutter.

The tray system wherein the central support member has a cross-sectioncomprising a top section configured to support the bottom of the peak ofeach of the valleys, a middle section comprising a bar, and a bottomsection configured with a first shelf extending from a first side of themiddle bar section, and a second shelf extending from a second side ofthe middle bar section.

The tray system wherein the first and second elongate side supportmembers comprise a bottom section comprising a shelf extending towardthe central support member.

The tray system wherein the first elongate hollow duct member issupported by the first shelf of the central support member and the shelfof the first side support member, and the second elongate hollow ductmember is supported by the second shelf of the central support memberand the shelf of the second side support member.

The tray wherein a set of the plurality of alternating parallel ridgescomprises a central boss supported by the central support member.

The tray system wherein the gutter is configured to be in fluidcommunication with a fluid drainage system.

The tray system wherein the first duct member comprises a top panel anda bottom panel, a side comprising a first elongate side member and aside comprising the middle section of the central support member, andthe second duct member comprises a top panel and a bottom panel, a sidecomprising a second elongate side member and a side comprising thesecond shelf of the central support member.

The tray system wherein the tray comprises a plurality of holes in asubset of the ridges and top surfaces of the first and second ductmembers comprise a plurality of orifices in fluid communication with theplurality of holes in the subset of the ridges of the tray to provideair flow out of the first and second duct members above the tray system.

The tray system wherein the tray comprises a plurality of holes in asubset of the ridges, the top surfaces of the first and second ductmembers comprise a plurality of orifices in fluid communication with theplurality of holes in the subset of the ridges of the tray, and theplurality of holes in the subset of the ridges are in fluidcommunication with a plurality of transverse duct members having aplurality of holes to provide air flow out of the first and second ductmembers above the tray system.

The tray system wherein bottom surfaces of the first and second ductmembers comprise a plurality of orifices to provide air flow out of thefirst and second duct members below the tray system.

The tray system wherein the tray comprises a plurality of holes in asubset of the ridges, top surfaces of the first and second duct memberscomprise a plurality of orifices in fluid communication with theplurality of holes in the subset of the ridges of the tray, and theplurality of holes in the subset of the ridges are in fluidcommunication with a plurality of transverse duct members having aplurality of holes to provide air flow out of the first and second ductmembers above the tray system; and bottom surfaces of the first andsecond duct members comprise a plurality of orifices to provide air flowout of the first and second duct members below the tray system.

The tray system further comprising: a first tray system and a secondtray system, wherein ends of the first and second tray system areconnected to each other to provide an integrated system of a pluralityof tray systems.

The tray system wherein the central support member and the first andsecond elongate side support members are configured to rest on a racksystem.

The tray system wherein the central support member comprises a t-slotextending the length of the central support member.

The tray system wherein the first and second elongate side supportmembers each comprises a t-slot extending the length of their respectivebottoms.

Other aspects include a tray, including any embodiments of a traydescribed herein.

One embodiment of the tray provides a tray for plant cultivation,comprising opposed end walls and opposed side walls defining a perimeterof the tray, and a raised region disposed within the perimeter of thetray; wherein the side walls of the tray extend below the raised regionto hold the raised region above a space defined by the side walls andthe raised portion and the end walls of the tray each comprise a cut-outopening configured to provide an opening into the space.

In an embodiment of the tray, the raised region comprises a plurality ofridges disposed between the side walls and parallel to the end walls andtop surfaces of the plurality of ridges define a level plane; and aplurality of valleys formed between adjacent ridges of the plurality ofridges, wherein one or more of the plurality of valleys are in fluidcommunication with a gutter.

Other aspects include a duct assembly, including any embodiments of aduct assembly described herein.

One embodiment of the duct assembly comprises one or more top panels;one or more bottom panels; a first elongate side support member and asecond elongate side support member, each engaged to the one or more toppanels and the one or more bottom panels; and one or more elongatecenter support members engaged with the one or more top panels and theone or more bottom panels, wherein the first and second side supportmembers, the one or more top panels, the one or more bottom panels, andthe one or more center support members define one or more air passagescomprising a first open end configured to be in fluid communication witha ventilation system and a second open end opposed to the first open endconfigured to optionally be closed or optionally be in fluidcommunication with a second duct assembly; and a plurality of orificesin the one or more air passages to distribute air out of the one or moreair passages.

Embodiments of these inventive concepts, including embodiments of theSummary or any other embodiments described herein, can be combined inany manner, and the descriptions of features in the embodiments pertainnot only to the devices of this invention, but also to the methods oruses of any of the devices of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosed aspects will hereinafter be described in conjunction withthe appended drawings, provided to illustrate and not to limit thedisclosed aspects, wherein like designations denote like elements.

FIG. 1 is a top perspective view of the tray system, according to anembodiment of the disclosed subject matter.

FIG. 2 is a plan view of a tray of the tray system, according to anembodiment of the disclosed subject matter.

FIG. 3 is a plan view of an alternate tray of the tray system, accordingto an embodiment of the disclosed subject matter.

FIG. 4 is a perspective view of a cross section of the tray shown inFIG. 3, according to an embodiment of the disclosed subject matter.

FIG. 5 shows a close-up end view of a stack of trays of the tray system,according to an embodiment of the disclosed subject matter.

FIG. 6 is a top perspective view of a duct assembly of the tray system,according to an embodiment of the disclosed subject matter.

FIG. 7A is an end view of the tray system, according to an embodiment ofthe disclosed subject matter.

FIGS. 7B and 7C shows close-up end views of the side and center supportmembers of the tray system respectively, according to an embodiment ofthe disclosed subject matter.

FIG. 8 is a plan view of the bottom of the tray system, according to anembodiment of the disclosed subject matter.

FIG. 9 is a perspective view of the bottom of the tray system, accordingto an embodiment of the disclosed subject matter.

FIG. 10 is a perspective view of the top of the tray system showingtransverse duct members, according to an embodiment of the disclosedsubject matter.

FIGS. 11A and 11B show elevation and perspective views, respectively ofa transverse duct member, according to an embodiment of the disclosedsubject matter.

FIGS. 12 and 13 are perspective views of the top of the tray systemshowing alternate transverse duct members, according to an embodiment ofthe disclosed subject matter.

FIGS. 14A and 14B show close-up views of a transverse duct member shownin FIG. 13, according to an embodiment of the disclosed subject matter.

FIG. 15 shows a first perspective cross-section view of the transverseduct member shown in FIG. 13 attached to the tray system, according toan embodiment of the disclosed subject matter.

FIG. 16A shows a second perspective cross-section view of the transverseduct member shown in FIG. 13 attached to the tray system, according toan embodiment of the disclosed subject matter.

FIG. 16B shows a perspective cross-section view of the transverse ductmember shown in FIG. 13 attached to the tray system comprising analternative turning vane, according to an embodiment of the disclosedsubject matter.

FIG. 16C shows a perspective cross-section view of the transverse ductmember shown in FIG. 13 attached to the tray system using a spring clip,according to an embodiment of the disclosed subject matter.

FIG. 17 is a top perspective view of a tray system connected to a fanassembly, according to an embodiment of the disclosed subject matter.

FIG. 18 is a top perspective view of a plurality of the tray systemsconnected end-to-end, according to an embodiment of the disclosedsubject matter.

FIG. 19 shows a fan assembly of the try system, according to anembodiment of the disclosed subject matter.

FIGS. 20A and 20B show views of the filter component of the fan assemblyof a ventilation system, according to an embodiment of the disclosedsubject matter.

FIG. 20C shows a view of a filter component of the fan assembly of aventilation system, according to an alternative embodiment of thedisclosed subject matter.

FIG. 21 depicts a view of a plurality of the tray systems connectedend-to-end on a rack system, according to an embodiment of the disclosedsubject matter.

DETAILED DESCRIPTION

Various aspects of the novel systems, apparatuses, and methods disclosedherein are described more fully hereinafter with reference to theaccompanying drawings. This disclosure can, however, be embodied in manydifferent forms and should not be construed as limited to any specificstructure or function presented throughout this disclosure. Rather,these aspects are provided so that this disclosure will be thorough andcomplete, and will fully convey the scope of the disclosure to thoseskilled in the art. Based on the teachings herein, one skilled in theart would appreciate that the scope of the disclosure is intended tocover any aspect of the novel systems, apparatuses, and methodsdisclosed herein, whether implemented independently of, or combinedwith, any other aspect of the disclosure. For example, an apparatus maybe implemented or a method may be practiced using any number of theaspects set forth herein. In addition, the scope of the disclosure isintended to cover such an apparatus or method that is practiced usingother structure, functionality, or structure and functionality inaddition to or other than the various aspects of the disclosure setforth herein. It should be understood that any aspect disclosed hereinmay be implemented by one or more elements of a claim.

Although particular aspects are described herein, many variations andpermutations of these aspects fall within the scope of the disclosure.Although some benefits and advantages of the preferred aspects arementioned, the scope of the disclosure is not intended to be limited toparticular benefits, uses, and/or objectives. The detailed descriptionand drawings are merely illustrative of the disclosure rather thanlimiting, the scope of the disclosure being defined by the appendedclaims and equivalents thereof.

The inventive concepts consist of a uniquely designed tray system, whichmay incorporate ductwork for de-stratification entirely within itsfootprint. The tray system can be constructed from a variety ofmaterials and may include a duct, or a plurality of ducts, that fitwithin the vertical and horizontal dimensions of the tray andincorporate a plurality of orifices distributed to deliver pressurizedgas (typically air, or air enriched with carbon dioxide) above, below orboth above and below the tray system, de-stratifying the growingenvironment of plants resting on the tray. The ductwork can be integralto or nested within the tray assembly.

The design of the tray and ducting assembly allows for efficientcirculation and de-stratification of the growing environment whiletrapping and consolidating excess water and nutrients, providing a levelsurface for supporting plant containers, and providing a flat lowersurface to facilitate the installation of lighting or other hardware.The tray assemblies are modular and designed to optionally attachend-to-end to create a continuous duct of a desired length.

The growing containers with plants therein sit on ridges on the top ofthe tray, with the duct assembly comprising top and bottom panels, lowerpanels and blowing orifices beneath the tray. In this way, air flowingthrough the duct assembly beneath and within the tray directs air upwardbeneath the leaf canopy of plants on the tray and/or downward to theleaf canopy of plants on another tray system below the tray system. Thetop surface of the tray is sealed off from the duct assembly andcollects water draining from the plants in the gutter(s) on the sides.Notably, no part of the drainage system, including the gutter, the drainor any tubing or piping attached to the drain passes through any part ofthe duct assembly.

As shown in FIG. 1 (see also FIGS. 7 and 10), the tray system comprisesa tray 10 comprising two open ends 11 and two sides 12, and comprising aplurality of alternating parallel ridges 13 and valleys 14 parallel tothe two ends 11, forming a corrugated region having a top surface and abottom surface. The walls of the open ends 11 of the tray 10 areconfigured to provide a space for the duct assembly 20 to nest into andbelow the bottom surface of the tray 10 below the valleys 14. The sides12 of tray 10 extend below the region of alternating ridges 13 andvalleys 14 so that tray 10 rests above duct assembly 20. The bottom ofthe perimeter of the tray proximate to the sides 12 and corners of thetray 10 may be generally flat, so that it can support the tray 10 whenrested on a surface such as a shelf or horizontal support members of aracking system (not shown, see FIG. 21).

The ridges being parallel to the ends of the tray is not limiting. Inother embodiments, the ridges may be parallel to the sides of the tray.In other embodiments, the ridges may be diagonal relative to the sidesand ends of the tray. Other embodiments of the tray do not require theridges to be parallel to one another. In their broadest sense, theridges define a generally level surface on which plant containers canrest on, and the valleys between the ridges generally slope downwardfrom one or more high points to a gutter having a drainage hole at thelowest point of the tray to collect and drain water from the tray.

Notably the plurality of alternating parallel ridges 13 comprise topsurfaces defining a level plane for supporting one or more individualgrowing containers for containing growth medium and plants, and thevalleys slope 14 downward from a peak, such as aligned with center ofthe tray as shown, to gutter(s) 15 proximate to the side(s) 12 of thetray 10, wherein the valleys 14 are in fluid communication with thegutter 15 for channeling fluid collected in the valleys 14 into thegutter 15. Fluid collected in the valleys 14 comprises excess (run-off)water and nutrients supplied to plants by drenching, flooding, dripirrigating or misting operations described further below.

For example, water may be delivered through polyvinyl chloride (PVC) orpolyethylene tubing that can be affixed to sides of a rack systemdescribed below and then delivered to each plant using a manifold systemand smaller diameter tubing with drip nozzles.

The parallel ridges 13 are designed to support a plurality of individualgrowing containers, for example, plastic or clay pots, while allowingfluid to drain, such as from the containers, into the valleys 14 and thegutter 15 without pooling. Preferably, the ridges 13 have a generallyflat top surface to provide a level surface for the growing containers.

The spacing between ridges 13 is configured to support growingcontainers having dimensions ranging from about 2 to about 8 inches(about 4 cm to about 20 cm), such as 6-inch (15-cm) square containers.Containers may be round, square, rectangular, hexagonal, octagonal, etc.Smaller containers would yield higher plant densities. Seeds may besprouted into seedlings and grown using trays with a plurality ofmolded-in receptacles until they are large enough to be transplantedinto larger containers. Plants are typically spaced at one container persquare foot, such as thirty-two plants on a standard 4 foot by 8 foot(about 1.2 meters by 2.4 meters) tray. Other tray sizes would scale bythis value.

The top surface of the tray 10 in the valleys 14 may slope downwardsfrom the center of the tray toward the sides of the tray. This slope isdesigned to drain fluid towards the gutter at the edges of the traywhere it is consolidated and drained, for example by means of attachedtubing or piping as described below. The alternating ridges 13 andvalleys 14 also stiffen the tray surface and transfer loads from thegrowing containers on the tray to the side and central support membersof the duct assembly 20 described further below.

Preferably, the tray 10 comprises a thin cross-section comprising acorrugated region of the alternating ridges 13 and valleys 14 so as toallow efficient molding using a vacuum or pressure process, wherein thetray 10 has a shape configured to nest above and around the ductassembly 20. The tray is designed to be molded from a variety ofpolymers or layers of polymers such as acrylonitrile butadiene styrene(ABS), polyvinyl chloride (PVC), acrylonitrile styrene acrylate (ASA),etc. or combinations thereof. In some embodiments, the tray may haveantimicrobial properties in order to maintain a relatively sterilegrowing environment. Additives in the polymer used in the manufacture ofthe tray 10 may provide improved antimicrobial properties. Somematerials appropriate to the construction of the tray (ABS, PVC, etc.)may have inherent antimicrobial properties. Alternatively, the surfaceof the tray may comprise a coating with antimicrobial properties,applied either before or after molding or forming the tray 10.

The design of the tray 10 incorporates the necessary draft angles on allsurfaces to allow for release from the mold. While the tray 10 is mostefficiently made from molded polymer, it would also be possible tofabricate it from a variety of materials such as stainless steel,aluminum, glass or composites such as fiberglass, etc.

As seen in FIGS. 2 and 3, the tray 10 has one or more drainage bosses 16in the bottom of the gutter 15. The drainage of excess water or liquidnutrients is accomplished by the angled slope of the valleys 14 andgutter(s) 15 incorporated into the tray. The drainage bosses 16 in thetray gutters may allow connection of fittings to tubes or pipes to drainaway the consolidated water and nutrients.

In the embodiment illustrated in FIG. 2, the tray 10 has four drainagebosses 16, one in each corner of the tray 10, but not all need to befunctional as drains. In the embodiment illustrated in FIG. 3, the tray10 a has two drainage bosses 16, one in each gutter 15 proximate to eachside 14 of the tray 10 a. As shown in FIGS. 2 and 3, the drainage bosses16 are circular but that is not limiting. Other shapes such as oval,square, rectangular or slit may also be envisioned. The drainage bosses16 may comprise a region of thicker molding to strengthen the tray and acenter that can be punched out to provide an opening or drainage holefor fluid to drain out of the gutter 15 into a drainage system.Alternatively, the tray may be molded with one or more opening(s)already present in the drainage bosses 16. In some embodiments, thedrainage hole is simply an opening to allow fluid to pass through todrain water into a gutter or drain pipe in the rack system. In otherembodiments, the drainage boss may be configured to be attached to thedrainage system such as by a fitment, e.g. a gasket, flanged insert orbarbed or threaded bulkhead fitting, to allow connection of pipe or tubefittings to drain away the consolidated water and nutrients. In otherembodiments, the tray may have a molded-in nipple which protrudes belowthe surface of the upper tray and allows the attachment of a barbed orthreaded pipe fitting using either a mechanical or solvent weldedconnection. In embodiments, one or more drainage bosses 16 are locatedin the side gutters 15 and positioned such that water flowing along thegutter 15 drains into the boss 16 and attached piping. The drain openingto drainage boss 16 may include a polymer or metal mesh or slottedfilter to prevent ingress of debris into the drainage system.

Tubing or piping attached to the drainage bosses 16 of one tray systemmay be run into a drainage gutter of another tray system on a lower tierof a rack system, or in the case of the bottom tier or alternateimplementation directly into a main drainage line on the bottom of therack system. This main drainage line may be sloped down to a buildingfloor drain.

In some embodiments, the excess water can be collected and sent to arecycle system for later reuse. Recycling the excess water can furthercomprise filtering, disinfecting (or other purification method) and/orreplenishing nutrients.

Preferably the tray 10 has dimensions to allow a user to convenientlylift and transport a tray and possibly growing containers restingthereon. Tray sizes may be configured depending on the type and size ofplants to be grown using the tray system and the growing rooms availableto a user of the tray system. In some embodiments, the tray 10 may haveabout 12 inches (about 0.3 meter), about 18 inches (about 0.45 meter),about 24 inches (about 0.6 meter), about 3 feet (about 0.9 meter) orabout four feet (1.2 meter) or wider. In some embodiments, the tray 10may have lengths of about 3 feet (about 0.9 meter), about four feet (1.2meter), about 6 feet (about 1.8 meter), about 8 feet (about 2.4 meter)long, about 10 feet (about 3 meters) or about 12 feet (about 3.7meters). In some embodiments, the tray may have a height of about 2inches to about 12 inches (about 5 cm to about 30 cm), preferably about4 inches to about 6 inches (about 10 cm to about 15 cm), such as about 5inches (about 13 cm).

In embodiments, tray dimensions may include 2 feet by 4 feet (about0.6×1.2 meter), 4 feet by 4 feet (about 1.2×1.2 meter) 4 feet by 8 feet(about 1.2×2.4 meter), 4 feet by 10 feet (about 1.2×3 meter) and 4 feetby 12 feet (about 1.2×3.7 meter). As described below, tray systems maybe connected end-to end to provide longer continuous runs.

As shown in FIG. 2, a subset of the ridges 13 may comprise intermittentflats on the upper surface of the tray to provide blowing bosses 30centered on the tray 10. As illustrated, the flats of the blowing bosses30 are configured as rounded rectangles, but that is not limiting. Theblowing bosses 30 are designed to allow access to a duct or ducts of theduct assembly 20 for the purpose of distributing air above the traysurface to the underside of the crop canopy from below if desired. Inthis embodiment, a cut or a plurality of cuts may be made in blowingbosses 30 to provide a plurality of openings 31 in the tray in fluidcommunication with a plurality of openings in a top surface of a duct,as described below, to provide air flow out of the ducts to above thetray system. In the exemplary embodiment shown in FIG. 2, optionally, acircular cut (shown as a dotted circle) could be made on each end of aflat blowing boss 30, concentric with the rounded ends of the blowingboss 30 to allow each opening 31 to be in fluid communication with aduct in the duct assembly 20.

In FIG. 3, a subset of the ridges 13 may comprise intermittent flats onthe upper surface of the tray to provide blowing bosses 32 extendingacross the corrugated region on the tray 10 a. In this embodiment, aplurality of openings can be made in blowing bosses 32 to provide aplurality of slots 33 separated by spacers 34 in the tray 10 a, whereinthe slots 33 are in fluid communication with a plurality of openings ina top surface of a duct, as described below, to provide air flow out ofthe ducts to above the tray system.

The number and location of the plurality of blowing bosses 30 or 32 andopenings 31 or 33 is not limiting, but may be dependent on the size andquantity of growing containers to be placed on the tray, the size of theplants therein, and the environmental conditions desired. When not usedto distribute air above the tray system, openings 31 or 33 can be sealedwith correspondingly-shaped plugs to close the openings.

FIG. 4 is a perspective view of a cross section of the tray 10 alongline A shown in FIG. 3, according to an embodiment of the disclosedsubject matter. The slope of the valleys 14 from the high point at thecenter of the tray 10 a to the junction of the valley 14 and the gutter15 is shown, and can be about 1 to 3 degrees down from horizontal. FIG.4 also shows optional stacking lugs 17 formed in the sides 12 of thetray 10 a.

In other embodiments the valleys 14 may slope from a first side of tray10 to the opposed second side to a single gutter 15 proximate to thesecond side in fluid communication with the valleys 14 to collect fluidfrom the top of tray 10. In these embodiments, the duct assembly 20would have a cross-section complementary to the slope of the valleys 14wherein the top of duct assembly 20 has a slope equivalent to the slopeof valleys 14.

In other embodiments the valleys 14 may slope down from a first side oftray 10 and a second side of tray 10 to a single gutter 15 proximate tothe central region of the raised portion of the tray in fluidcommunication with the valleys 14 to collect fluid from the top of tray10. In these embodiments, the duct assembly 20 would have across-section complementary to the slope of the valleys 14 wherein thetop of duct assembly 20 has a slope equivalent to the slope of valleys14.

FIG. 5 shows a close-up end view of a stack of trays 10 of the traysystem. The trays 10 can nest together for shipping and/or storage, inwhich the optional stacking lugs 17 on each tray separate the trays sothat the trays can be easily unstacked. For example, the stacking lugs17 can be sized to separate the trays with a separation of about 0.66inch (about 1.7 cm) between each tray. This number would be tailored tothe material thickness and draft angles present on the molded traysurfaces to ensure a minimum separation distance of around 0.030 inch atall points between the trays.

In some embodiments, a tray 10 as described herein can be used withoutbeing engaged to or nested above a duct assembly 20. For example, a tray10 can be used to carry plants from one location to another in a growingoperation without the duct assembly 20. In another example, a tray 10can be used in a single-tier growing space or when plants are small,wherein air distribution within the growing environment does not need tobe directed out of a duct assembly 20.

In some embodiments, the tray may comprise one open end and one closedend such that the closed end does not provide an opening configured toprovide access to the duct assembly. In other embodiments, the tray maycomprise two closed ends.

In embodiments, the duct assembly 20 nests within or below the tray 10.In the embodiments shown in FIG. 1, the duct assembly 20 is nestedwithin and below the tray 10 and is a separate assembly.

FIG. 6 shows a top perspective view of an exemplary embodiment of theduct assembly 20 with tray 10 removed. The duct assembly is designed tonest within the tray system under the tray 10, necessitating that theupper surfaces of the duct assembly 20 be angled to accommodate thedraining feature of valleys 14 of the tray 10, which are sloped tocollect and concentrate the excess water and nutrients. In theembodiment shown, the cross-section of the two ducts 20 a and 20 b ofthe duct assembly 20 may generally be trapezoidal with a flat bottom andsides and an angled top. Typically, the ducting 20 will be laid downfirst with the tray 10 positioned (resting) on top. As describedelsewhere herein, the duct assembly can also be used by itself, with notray, and positioned above the top tier of trays to provide downwardairflow and lighting mounting points.

Preferably, the fit is snug and contact is required between the ductassembly 20, including center support member 26 and side support members27 a, 27 b, and tray 10 in order to transfer load from the weight ofplant containers on the upper surface of the tray 10 to a supportingrack system. Notably, the tray 10 and duct 20 are not permanentlyattached or sealed together to facilitate switching upper trays 10 whileleaving the duct assembly 20 in place on the rack system.

In the embodiment shown in FIG. 6, the duct assembly 20 is constructedof flat top panels 21 that form the top of the duct assembly 20, flatbottom panels 22 that form the bottom of the duct assembly 20, a centersupport member 26 and side support members 27 a and 27 b. Flat panels 21and 22 may be made from polymer, composite or metal. Preferably the ductassembly panels can be made of plastics such as PVC, ABS, ASA,polycarbonate, polyethylene, etc. Notably, expanded PVC can be used dueto its low cost and stiffness. FIG. 6 shows that the top panels 21 mayoptionally comprise holes that are in fluid communication with optionalholes 31 or 33 in the tray 10 or 10 a to provide air flow above the traysystem. In the embodiment shown, the holes 23 in the top panels 21 arealigned with corresponding slots 33 in tray 10 a. In other embodiments(not shown), the holes in top panels 21 are aligned with correspondingholes 31 in tray 10. In still other embodiments (not shown), the toppanels 21 do not have holes and air would not be delivered above thetray system.

The function of the center and side support members 26, 27 a and 27 b isto provide connectors for the top and bottom panels 21 and 22, as wellas to serve as a load path from the underside of the upper tray 10 toperpendicular horizontal support members on a rack system such as shownin FIG. 21.

In the embodiment illustrated in the Figures, the edges of the top andbottom duct panels 21 and 22 are attached to the center 26 and sidesupport members 27 a and 27 b by insertion into slots at the top andbottom of the center and side support members.

To provide adequate support for the upper tray and plant containers, thesupport members are typically fabricated from a variety of materialssuch as stainless steel, aluminum, alloys or carbon composites, etc.Notably, the support members are configured to be elongate with aconsistent cross-section along their length, allowing for theirfabrication as extrusions. Preferably, the center and side supportmembers are aluminum extrusions. The extrusions that form the center andside support members form the primary load path to horizontal supportmembers on a rack system, allowing the material (e.g. panels 21 and 22)making up the bulk of the air ducts to be non-structural.

The top panels 21 and bottom panels 22 are releasably engaged with thesupport members 26, 27 a and 27 b so that the duct assembly can bedisassembled to interchange top panels 21 and/or bottom panels 22 tomodify the air distribution out of the ducts 20 a and 20 b to direct airabove the tray system, below the tray system or both above and below thetray system. Disassembly also allows for easy cleaning and/or compactstorage of the components of the duct assembly 20.

FIG. 7A shows a cross-section of an embodiment of the tray system, suchas along line A shown in FIG. 3, and FIG. 7B shows enlargedcross-sections of center support member 26 and side support member 27 a.One can appreciate that side support member 27 b comprises the samecross-section as 27 a, except that the cross-section is flippedhorizontally. As shown in FIG. 7A, tray 10 rests on top of supportmembers 26, 27 a and 27 b and over duct assembly 20. Duct assembly 20 isvisible through the open ends 11 of tray 12.

In the embodiment shown in FIG. 7B, the central support member 26 has across-section comprising (i) a top section configured to support thebottom of the peak of each of the valleys 14 and connect to the top ductpanels 21, (ii) a middle section comprising a bar 26-1, and (iii) abottom section configured with a first shelf 26-extending from a firstside of the middle bar section, and a second shelf extending from asecond side of the middle bar section. The top section comprises a firstupper shelf 26-2 extending from one side of bar 26-1 and a second uppershelf 26-3 extending from the opposed side of bar 26-1. The top sectionalso comprises a first upper flange 26-4 extending from one side of bar26-1 and a second upper flange 26-5 extending from the opposed side ofbar 26-1. First upper shelf 26-2 and first upper flange 26-4 form a slotthat engages a first top panel 21. Second upper shelf 26-3 and secondupper flange 26-5 form a slot that engages a second top panel 21.Preferably the shelf is longer than the flange to create a surface torest the panel on before seating the entire length in the slot. Thisgreatly eases assembly.

The bottom section comprises a first lower shelf 26-6 extending from oneside of bar 26-1 and a second lower shelf 26-7 extending from theopposed side of bar 26-1. The bottom section also comprises a firstlower flange 26-8 extending from one side of bar 26-1 and a second lowerflange 26-9 extending from the opposed side of bar 26-1. First lowershelf 26-6 and first lower flange 26-8 form a slot that engages a firstbottom panel 22. Second lower shelf 26-7 and second lower flange 26-9form a slot that engages a second bottom panel 22.

In an alternative embodiment of center support member 26, bar 26-1 maybe replaced by two bars, one bar connecting the ends of first uppershelf 26-2 and first lower flange 26-8 and a second bar connecting theends of second upper shelf 26-3 and second lower flange 26-9. In thisembodiment, the two bars may provide extra vertical support to the tray10, and in combination with the upper shelves and the lower flanges,define a lumen in center support member 26.

In the embodiment shown in FIG. 7B, the first and second elongate sidesupport members 27 a and 27 b each comprise a generally triangular ortrapezoidal cross-section comprising (i) a top section configured tosupport the bottom of each of the valleys 14 proximate to their junctionwith gutter 15 and connect to the top duct panels 21, (ii) a middlelumen section, and (iii) a bottom section 27-3 configured to connectwith a bottom duct panel 22. The top section comprises an upper shelf27-5 extending from one side of bar 27-1. The top section also comprisesan upper flange 27-6 extending from the side of bar 27-1. Upper shelf27-5 and upper flange 27-6 form a slot that engages a top panel 21.

First bar 27-1 is configured to be vertical and bounds one side of theducts 20 a or 20 b opposite the side bounded by the bar 26-1 of thecenter support member 26. Second bar 27-2 may be configured to join thetop section and the bottom section and is configured to support the tray10 proximate to the region of the gutter 15. A shown, second bar 27-2 isconfigured to be sloped and curve toward the top and bottom sections,but that is not limiting. The middle section comprises a lumen 27-4bounded by a first bar 27-1, second bar 27-2 and the bottom section.

The bottom section comprises a lower shelf 27-7 and a lower flange 27-8above lower shelf 27-7, each extending from one side of bar 27-1 towardthe center of the tray system. Lower shelf 27-7 and lower flange 27-8form a slot that engages a bottom panel 22.

Optionally, as shown in FIGS. 7A and 7B, the support members 26, 27 aand 27 b may also incorporate a feature (in the embodiments shown a“t-slot”) 29 along the bottom surface to allow the installation of hooksor fittings to hold lighting and/or other equipment. Embodiments includethose wherein the central support member 26 comprises a t-slot extendingthe length of the central support member. Embodiments include thosewherein the first and second elongate side support members 27 a and 27 beach comprises a t-slot extending the length of their respectivebottoms. The t-slots 29 can also serve as a fastening feature betweenduct sections as discussed further below with the use of a connectorwhich fits within the slot and bears between the inside of the slot andthe top on each support member section. The t-slots 29 may also be usedto attach the duct assembly 20 to horizontal support members on a racksystem.

Optionally, as shown in FIGS. 7A and 7B, the support members 26, 27 aand 27 b may each also comprise one or more small lumens, depicted asopen circles 40. Lumens 40 can also serve as a fastening feature betweenduct sections as discussed further below with the use of a connectorconfigured to fit within the lumens 40 and extend into the insides oflumens 40 on tray systems laid end-to-end. These may be used asalignment features with a pin spanning the two extrusion sections andprecisely aligning the extrusions so that the t-slot clamp does not needto index the extrusions, only provide the mechanical fastening function.

As described above, alternative embodiments comprise valleys 14 slopingfrom a first side of tray 10 to the opposed second side to a singlegutter 15. In these embodiments, side support members 27 a and 27 bwould not have the same cross-section, wherein one side support memberwould be taller than the other and a top section sloping downward andthe other would have a top section sloping upward. The center supportmember 26 would have top section that comprises a single sloped top. Inother such embodiments, the center support member 26 may be eliminatedand a single top panel 21 and a single bottom panel 22 are engaged toside support members 27 a and 27 b to provide a single duct in ductassembly 20.

In other embodiments the valleys 14 may slope down from a first side oftray 10 and a second side of tray 10 to a single gutter 15 proximate tothe central region of the raised portion of the tray in fluidcommunication with the valleys 14 to collect fluid from the top of tray10. In these embodiments, the duct assembly 20, the side support memberswould be taller than the center support member and would have a topsection that slopes downward to the center of the duct assembly, and thecenter support member would have a top section wherein sides of theslope upward toward the sides of the duct assembly.

Lumens in side support members 27 a and 27 b, and a lumen in analternative embodiment of center support member 26 described above maybe used as conduits to conduct fluid such as water or nutrient solutionsto an irrigation system, or contain other components such as electricalwiring. For example, lumens in side support members 27 a and 27 b maycontain wires to supply power to lights mounted in t-slots 26 (see FIG.9) and a lumen in center support member may conduct water to anirrigation system.

As shown in FIGS. 8 and 9, in some embodiments the bottoms of the ducts20 a and 20 b may comprise a plurality of orifices 24 in the bottompanels 22 to allow air to be distributed from a ventilation systemthrough the ducts and onto plants below the tray system in a verticalgrowing system. The orifices may be round, oval shaped, rectangular,slotted etc. In other embodiments the bottom panels 22 do not compriseorifices 24 and air cannot exit from the bottom of ducts 20 a and 20 b.The distribution of orifices 24 in bottom panels 22 may be based on thedesired flow capacity of the blowing system.

FIG. 9 shows LED lights 45 shown attached to the t-slots 29 in thebottom of side support members 27 a and 27 b to provide light for plantson a tray system below the tray system shown. Wiring to supply power tothe LED lights 45 can be run through the lumen in the side supportmembers or in wiring tape run through the t-slots 29. The number and/orwattage of the LEDs and the wavelength emitted can be customized withadjustable cable gland quantity and placement according to the needs ofa user of the tray system. Tubing (not shown) may be hung from thet-slot 29 in center support member 26 to supply water to nozzles oremitters to provide irrigation to plants growing on a tray below thetray system shown.

In some embodiments, a duct assembly 20 in combination with aventilation system 50 can be used in the absence of tray 10 todistribute air in a vertical growing space. For example, a duct assembly20 by itself without being nested below a tray 10 can be used for atopmost tier of a growing space. The duct assembly 20 would blow down onthe tops of the plants on the next lower tier and provide mounting forlighting and/or irrigation systems. In these embodiments, air can beblown up, down, or both up and down and using the duct assembly 20without tray 10, using holes 23 and/or 24 of the duct assembly 20.

In some embodiments, the tray system may further comprise transverseduct members inserted into holes 31 or 33 in the tray 10 such that theyare in fluid communication with holes 23 in the top panels 21 of theduct system to provide an avenue for air to be emitted above the tray 10and under the leaf canopy of plants growing on top of the tray.Embodiments of transverse duct members are shown in FIGS. 10 through 16.

FIG. 10 show a first embodiment of a transverse duct member 60,comprising a central housing 61 and two hollow tubes 62 extending inopposite directions from housing 61. One or a plurality of transverseduct members 60 (four are shown) are inserted into holes 31 in the tray10 (See FIG. 2). As shown, not all holes 31 need to be used for thetransverse duct members 60. Holes 31 not occupied by transverse ductmember 60 can be plugged with stoppers 36 so that air cannot flow out.FIG. 11A shows a cross-section of the tray system comprising thetransverse duct member 60 and FIG. 11B shows a perspective view of thetray system comprising the transverse duct member 60. Central housing 61is shown as transparent for ease of presentation and may be configuredas a thin arch-shaped shield. Hollow tubes 62 each comprise a pluralityof holes 63 to emit air from the tubes 62 above the tray system and arecapped with end caps 64. The number and size of the holes 63 are notlimited to those shown in the Figures, but may be dependent on thedesired air flow for the type of plants grown on the tray system. Hollowtubes 62 are each releasably connected in fluid communication to acurved hollow tube section 65 that in turn is connected in fluidcommunication to a straight hollow tube section 96. Tubes 62 can beinterchanged to customize the number and/or placement of holes 63 in thetransverse duct member 60. The holes 63 are desirably placed on theupper side of hollow tube 62 to minimize water from an overheadirrigation system from entering the duct 60. Hollow tube sections 96 areinserted through holes 31 of tray 10 and holes 23 of top panels 21 intothe ducts 20 a and 20 b to provide a pathway for air to flow out of theducts 20 a and 20 b, through tube sections 66, tube sections 65, andtubes 62 and out of holes 63 to provide ventilation below the leafcanopy of plants grown on the tray system. Air scoops 67 on the ends oftubes 66 are configured to gather air flowing down the duct assembly 20from the ventilation system 50 and channel it into the transverse ductmember 60. An elastomeric sealing flange or gasket 68 seals the tubes 66to the inner surfaces of holes 23 and optionally holes 31 to minimizeair loss. The components of transverse duct member 60 may independentlybe made of plastic or metal. In some embodiments, tubes 62 may comprisealuminum extrusions. Tube sections 65, 66 and air scoops 67 may compriseseparate pieces, but may be preferably integrated into a single moldedpiece.

FIG. 12 shows an alternative embodiment of a transverse duct member 60b. In this embodiment, the transverse duct member 60 b comprises asingle hollow tube 62 b with a plurality of openings 63 b on its sides.In the embodiment shown the hollow tube 62 b has a triangular crosssection, but in other embodiments, the tube may have trapezoidal orarched cross-sections. Tubes 66 b are similar to tube sections 66 of theprevious embodiment, but may connect to holes in the bottom of tube 62 binstead of curved tube sections 65. In this embodiment, air scoopssimilar to air scoops 67 and gaskets similar to gasket 68 areenvisioned. The height of tube sections 66 or 66 b may be varied toallow for customizing the height of the holes 63 or 63 b above the tray10, dependent on the height of plant containers and leaf canopy ofplants growing on the tray system.

FIGS. 13 through 16 illustrate aspects of another embodiment of atransverse duct member 60 c. In this embodiment, the transverse ductmember 60 c comprises an arch-shaped elongate member 62 c having an openbottom that engages a blowing boss 32 on tray 10 a (see FIG. 3), shownin FIG. 13. FIG. 14A shows a close-up top perspective view of theelongate member 62 c, which comprises a plurality of openings 63 c on anupper side of member 62 c. Caps 64 c close both ends of elongate member62 c. FIG. 14B shows a close-up bottom perspective view of an end of theelongate member 62 c showing open bottom 62 c-1. A flange 62 c-2comprising gasket 69 is configured to engage the top and sides ofblowing boss 32, as best seen in FIG. 16A.

FIG. 15 shows a first perspective cross-section view of the transverseduct member 60 c engaged to blowing boss 32 along line B shown in FIG.3. Holes 33 in tray 10 are aligned with holes 23 in top panel 21 so thatair can flow out of the duct assembly 20 through holes 23 and 33 and theopen bottom 62 c-1 into the body of elongate member 62 c and thenthrough holes 63 c to exit above the tray 10 and below the leaf canopyof plants growing thereon. Optional pad 70 on the bottom of blowing boss32 rests on top panels 21 of duct assembly 20 to minimize vibrationcaused by airflow through the tray system.

FIG. 16A shows a second perspective cross-section view of the transverseduct member 60 c engaged to blowing boss 32 along line C shown in FIG.3. The height of member 62 c may be varied to allow for customizing theheight of the holes 63 or 63 b above the tray 10, dependent on theheight of plant containers and leaf canopy of plants growing on the traysystem. Also shown in FIG. 16 is a turning vane 75 that engages theopening in the top panel 21 to divert air flow through the duct assembly(shown as an open arrow) into the bottom of member 62 c via holes 23, 33and open bottom 62 c-1. As shown in the inset, turning vane 75 comprisesa vertical section 75 a that is configured to extend through holes 23,33 into the open bottom 62 c-1 in the transverse duct member 62 c, acurved section 75 b that extends into a duct of the duct assembly 20 todirect the air flow. Flanges 75 c and 75 d define a slot 75 e thatreleasably engages top panel 21.

In an alternative embodiment shown in FIG. 16B, a turning vane 76 maycomprise an air passageway defined by a short side 76 a, a long side 76b and two ends 76 d dimensioned to fit within and pass through the innersurfaces of holes 23 and 33 and extend into open bottom 62 c-1. Curvedportion 76 c directs air flow from the duct assembly into the transverseduct member. A sealing gasket 69 can engage the blowing boss 32 of tray10 a around the perimeter of a hole 33 and optionally the inner surfaceof a hole 23 in top panel 21. In this embodiment, the turning vane 76may be configured similar to the structure comprising a tube 66, airscoop 67 and sealing flange 68 of the transverse duct member 60 a shownin FIGS. 14A and 14B, except having a rectangular cross-section.

FIG. 16C shows a perspective cross-section view of the transverse ductmember shown in FIG. 13 attached to the tray system using a spring clip77, according to an embodiment of the disclosed subject matter. Thespring clip 77 may comprise a thin, resilient strip of metal or plasticconfigured to engage the open bottom 62 c-1 of the elongate member 62 cand an opening 33 in blowing boss 32. This clip 77 is not limiting, andother attachment mechanisms can be used.

In FIGS. 13 and 15, transverse duct member 60 c is shown as extendingthe full length of blowing boss 32 and in fluid communication with bothducts 20 a and 20 b of duct assembly 20, but this is not limiting. Insome embodiments, transverse duct member 60 c may be shorter, having alength less than half the length of blowing boss 32 and in fluidcommunication with only one duct in duct assembly 20.

In some embodiments, the tray system may comprise one or more ductmembers configured to engage a subset of holes 31 or 33 in tray 10 thatare disposed perpendicular to ends 11 and parallel to the sides 12 oftray 10, and a set of corresponding holes 23 in top panel(s) 21 of theduct assembly 20 and direct air above the tray system. Air flow withinthese parallel duct members is also parallel to the air flow within theduct assembly 20. For example but not limitation, parallel duct membersmay engage holes proximate to the sides 12 of tray 10 and/or the centerof tray 10. Design principles of embodiments of the parallel ductmembers are similar to those discussed above for transverse duct members60, modified to reflect the different orientation of the parallel ductmembers.

In some embodiments, the tray system may comprise a combination oftransverse and parallel duct members.

Each end of the duct assembly 20 is configured to releasably connect toa ventilation (blowing) system 50 or to another duct assembly 20 in anend-to-end configuration (see FIGS. 9, 17 and 18). As shown in FIGS. 9,17 and 18, one end of the duct assembly 20 is engaged with a ventilationsystem 50 such that duct assembly 20 is in fluid communication with theventilation system 50 so that air can be driven by the ventilationsystem the length of the ducts within the duct assembly 20 and throughholes 23 in top panel 21 to distribute air above the duct assembly 20through holes 24 in bottom panels 22 to distribute air below the ductassembly 20, or through holes 23 in top panel 21 and through holes 24 inbottom panels 22 to distribute air above and below the duct assembly 20.

The ends of the ducts may comprise a fitment to connect to theventilation system 50 or to each other. For example, the fitment maycomprise an elastomeric sleeve configured to engage the inside of ducts20 a and 20 b and a corresponding opening in the ventilation system 50.In an embodiment, the airbox 51 (see FIG. 19) has a flange which fitstight against the end of the duct. The t-slots are then used with angledbrackets to bolt directly onto the airbox 51. Individual duct-to-ductconnections are made using the pins and t-slots, as well as an“H”-shaped extrusion where each opening in the H engages one of thepanels. One end of duct assembly 20 can be connected to the ventilationsystem 50 as shown in FIGS. 9 and 17 and the other end opposite theventilation system 50 can be closed with a cap (not shown), to preventair flow out of that end of the duct assembly 20, and instead air flowsout of orifices 24, when present, and/or holes 23, when present. The endplate (cap) at the distal end of the duct can be attached directly tothe small alignment holes or lumens 40 in the support member extrusionswith screws threaded into the holes.

In other embodiments, the tray systems may be connected end-to-end asshown in FIG. 18 to provide a longer growing platform in a rack system.In the embodiment shown, three tray systems 10-1, 10-2 and 10-3 areconnected end-to-end. In some embodiments, each tray 10 can have its ownrespective duct assembly 20. In the embodiments shown in FIGS. 17 and18, the tray systems comprise a plurality of transverse duct members 60b, but this is not limiting.

The duct assemblies 20 that nest within the trays 10 may be connectedtogether by means of connectors inserted in the “t-slots” 29 and/or pegsinserted into the circular lumens 40 in the cross-sections of the sideand center support members. The joints between support members 26, 27 aand 27 b and top panels 21 and bottom panels 22 may be staggered.Staggered joints will allow one extrusion or panel section to supporttwo or more trays, to provide stiffness to the overall assembly oftrays. In other embodiments, the ducts 20 may be configured as acontinuous duct disposed under a plurality of trays 10. The trays 10 arenested on top of but not vertically constrained by the ducts 20.Individual trays 10 (e.g. tray 10-1) can be removed (lifted) from theduct assembly 20, wherein the duct assemblies 20 are configured asconnected end-to-end or as continuous ducts.

Preferably, the distribution and size of orifices 24 in bottom panels22, when present, holes 23 in top panels 21, when present, and/or holes31 or 33 in tray 10, when present, can be tailored to maintain aspecific flow distribution. The orifices 24, when present, and/or holes23 in top panels 21, when present, may vary in size or density along thelength of the duct assembly 20 so as to maintain an equal flowdistribution along the duct length. As the air travels along the lengthof the duct, pressure is lost due to air exiting the duct, friction andother factors that results in a higher duct pressure at the end or endsfeaturing the blowers and tapering off along the length of the duct. Bytailoring the size or quantity of the orifices it is possible to evenout the air distribution over long lengths of duct assembly 20. Analysisof air flow within the ducts 20 a and 20 b allows tuning the size anddistribution of orifices to meet the requirements for growing plants.One can appreciate that the distribution may be different for differentplants and growing conditions.

In some embodiments, the duct assembly or assemblies 20 can be connectedat both ends to a ventilation system 50, such as when the ductassemblies comprises long duct runs. Ventilation systems 50 at both endsof the duct assembly 20 can drive air toward the middle of the duct runand even out air distribution along the entire duct run.

Generally, the ventilation system 50 may comprise air passage(s)configured to be connected to and in fluid communication with theduct(s) of the duct assembly 20. One or more fans can drive air throughthe air passages into the ducts of the duct assembly 20 and out holes inthe top panels 21 and/or bottom panels 22 of the duct assembly 20. Theventilation system can optionally comprise one or more components thatcan amend the air as desired before it enters the duct assembly 20selected from filters, heaters, coolers, dehumidifiers, humidifiers, CO₂injection, ozone injection or ultraviolet lights, the latter two ofwhich can be used to neutralize mold spores or pathogens.

Aspects of an embodiment of a ventilation or blowing system 50 are shownin FIGS. 19 and 20. In this embodiment, the ventilation system 50comprises an air box 51 (shown as transparent for ease of presentation)comprising an air passage wherein a first end 52 is configured to engagean end of the duct assembly 20 and the other end 54 is configured toaccept a fan 55. The intake filter is attached to the intake side of thefan 55, and the outlet side of the fan feeds the air box 51. In someembodiments a single fan is mounted in the center of the airbox and itsflow is split by the center support in the airbox 51 and fed to bothducts. In the embodiment shown, opening 52 and opening 54 are orientedat 90 degrees (perpendicular) relative to each other and the air passagecomprises one or more turning vanes 53 to efficiently turn the air 90degrees while constricting down to match the opening in the tray ductswhile reducing pressure loss. The fan is compressing the air in thiscase. There will be an acceleration and velocity increase through theturning vanes and constriction which will serve to lower the staticpressure but increase the dynamic pressure. The turning vanes aredesigned to minimize losses while this transition is occurring. The airbox may include CO₂ injection, ozone injection and/or ultraviolet lightbars. The perpendicular orientation of openings 52 and 54 is notlimiting and can be at any angle, or parallel, and the turning vanes 53configured accordingly. A bell-shaped inlet 56 at the intake passage inthe fan 55 opposite opening 54 draws ambient air through a filterassembly 57. In other embodiments, filter(s) may be disposed in the airpassage of the airbox 51.

FIGS. 20A and 20B show a cut-away view and a plan view, respectively, ofthe filter assembly 57. In FIG. 20A, the filter assembly 57 comprises adomed framework 58 attached to the inlet 56. The framework 58 supports adome-shaped filter 59 that filters ambient air as it enters theventilation system 50. The filter 59 may be disposable or preferablyreusable. FIG. 20B shows an overhead plan view of the inlet 56 andframework 58. The domed filter provides an increased filter areacompared to a flat filter, but the dome configuration is not limiting.Alternatively, the filter may comprise a cylinder filter that isdesigned to take a foam outer filter, or a cartridge element filter. Forexample as shown in FIG. 20C, in other embodiments the filter assembly57A may comprise a hollow cylinder of filter medium 59A supported by aframework of narrow ribs 58B in the shape of a cylinder. Inlet 56A maybe adapted to support a filter cartridge (not shown) and may beconfigured to engage a fitting on the filter cartridge. The housing isconverted to accept the cartridge element by removing the support rodsrunning between the top and bottom housing. Notably, the cross sectionof the air passage through the entire ventilation system 50 graduallydecreases in cross section and angle, reducing pressure losses andincreasing efficiency.

In the embodiment shown, each of ducts 20 a and 20 b of the ductassembly is fed air from one structure shown in FIGS. 19 and 20 (seealso FIGS. 17 and 18). In other embodiments, the elements of thestructure shown in FIGS. 19 and 20 may provide air to a plurality ofducts in duct assemblies 20 from a single unit. For example, a centralventilation system can collect and treat ambient air and deliveryconditioned air to a plurality of ducts in duct assemblies 20 via amanifold or network of pipes or tubing.

The disclosed tray systems can be supported in one or more tiers of arack system in which they are installed. A rack system generallycomprises a stationary or mobile platform comprising a plurality ofvertical support members or posts and horizontal side members connectedthereto and which are arranged in one or more tiers to allow multiplegrowing levels. The side members typically connect to a support post on8-foot (2.4 meters), 10-foot (3 meters) or 12-foot (3.7 meters)intervals. The side members are connected to two or more cross membersper span, which lay perpendicular to the long axis of the rack systemand support the duct extrusions (support members 26, 2 a and 27 b) ofthe duct assembly 20 in two or more places. The spacing between tiersvaries based on plant height but can range from 1 foot (0.3 meters) to16 feet (4.9 meters), preferably having a spacing between 1 foot (0.3meters) and 8 feet (2.4 meters), such as a spacing of around 4 feet (1.2meters).

The tray may be captured by raised edges of side members making up therack system if they are present, wherein the edges of the rack tierprevent the tray 10 from translating side to side or front to back. Theduct 20 may also be constrained by the tray(s) 10 it nests within.Alternatively or additively, the duct assembly 20 may be attached to therack system by means of clamps bearing on the cross members and mountingin the t-slots 29 of the support members 26, 27 a and/or 27 b. The ductassembly 20 would be placed and aligned on the rack cross members andthen clamped in place with clamps engaged in the t-slots 29. When theduct assembly 20 is locked to the rack system, it can also restrainmovement of a tray 10 disposed above the duct assembly 20.

In an embodiment, the rack system is configured to have a single traysystem supported at each level of the rack system. In this embodiment,the lengthwise dimensions of the tray 10 and the duct assembly 20,including the top and bottom panels 21, 22, and support members 26, 27 aand 27 b, are generally the same and may be slightly shorter than thelength of the tier. In another embodiment, the rack system is configuredto have a plurality of tray systems connected end-to-end supported ateach level of the rack system. In this embodiment, the lengthwisedimensions of a tier in the rack system may be slightly larger than thecombined lengths of the trays 10 and the duct assemblies 20, includingthe top and bottom panels 21, 22, and support members 26, 27 a and 27 b.In other embodiments, the rack system is configured to have a pluralityof tray systems side-by-side supported at each level of the rack system.

FIG. 21 shows a representative rack system 80 comprising a platform 81with a raised perimeter 82 and bottom 83 to provide a basin to retainexcess water drained from trays 10 placed on the rack system 80. A wiregrid 84 can support a tray system 10 (not shown in this view) as alowest tier of the rack system 80. Vertical posts 85 are slidinglyengaged to raised perimeter 82 so that their spacing can be adjusted.Cross members 86 engaged to posts 85 support trays 10 in a raised tierof the rack system 80. Cross members 86 can be moved up or down on thevertical posts 85 to adjust the height of the tier above platform 81.Two trays 10 laid end to end are shown in this view, each supported bytwo cross members 86. Duct assemblies 20 underlying the trays 10 areobscured in this view, but are also supported by the cross members 86. Aventilation system 50 as shown in FIG. 19 proximate to side 11 of tray10 is connected in fluid communication to the duct assembly 20 throughthe open wall of side 11. A plant 90, for example a poinsettia, in acontainer is shown on one of the trays 10. Transverse duct members 62 dare shown, which are similar to the embodiment of a transverse ductmember shown in FIGS. 11-13, absent housing 61.

Additional embodiments include systems that incorporate thede-stratification duct assembly 20 nested under the bottom of the tray10 and include additional components to provide the growing plants to bedrenched, flooded, drip irrigated or misted with water and nutrientstherefrom; and/or components such as growth lamps to provide light forphotosynthesis.

In another aspect, also provided is a method for cultivation of plants,the method comprising: providing a tray system according the tray systemdescribed above, including any embodiments disclosed herein, alone or inany combination; connecting the duct assembly of the tray system to aventilation system; connecting the tray to a fluid drainage system;placing a container containing growth medium and viable plant materialon the tray of the tray system; flowing air from the ventilation systemthrough the duct assembly and out of the plurality of orifices;providing water or liquid plant nutrient to the plant material; andcollecting excess water or liquid plant nutrient in the raised region ofthe tray and conveying the excess water or liquid plant nutrient intothe fluid drainage system via a gutter.

This aspect comprises the following embodiment. A method for cultivationof plants, the method comprising: providing a tray system as describedabove, including any or all embodiments; connecting the tray system to aventilation system and a fluid drainage system; placing a containercontaining growth medium and viable plant material on the ridges of theupper tray of tray system; flowing air from the ventilation systemthrough the first and second hollow elongate duct members and out theplurality of orifices; providing water or liquid plant nutrient to theplant material; and collecting excess water or liquid plant nutrient inthe valleys of the upper tray and conveying the excess water or liquidplant nutrient into the fluid drainage system via the gutter.

Disclosed herein is method for cultivation of plants, the methodcomprising, providing a tray system as described herein comprising atray 10 and a duct assembly 20, comprising any or all embodimentsdescribed herein, alone or in any combination; connecting the ductassembly of the tray system to a ventilation system and the tray to afluid drainage system; placing a container containing growth medium andviable plant material on the tray of the tray system; flowing air fromthe ventilation system through the duct assembly 20 and out a pluralityof orifices disposed on the duct assembly 20; providing water or liquidplant nutrient to the plant material; collecting excess water or liquidplant nutrient in the valleys of the tray; and conveying the excesswater or liquid plant nutrient into the fluid drainage system viavalleys and a gutter disposed on the tray.

Plants that can be grown or cultivated in the method comprise decorativeplants such as flowering plants or plants with decorative foliage, suchas for example poinsettias, roses, carnations, daffodils, tulips,lilies, chrysanthemums, violets, succulents, cacti, ferns, bromeliads,etc.; or herb or crop plants such as rosemary, oregano, basil, spinach,lettuce, cabbage, kale, cannabis, etc. Plants can be propagated orsprouted from seeds, bulbs, tubers, spores, etc., and grown to any stageup to and including full size and maturity in containers placed on thetray system.

What is claimed is:
 1. A system for plant cultivation, comprising: aventilation system comprising an air passage and an air box, the airpassage comprising a fan having an intake side and an outlet side, andthe air box comprising a first end and a second end, the first end ofthe air box comprising one or more air passages and the second end ofthe air box connected to the outlet side of the fan; a duct assemblycomprising one or more air passages, the duct assembly having a firstend in fluid communication with the ventilation system, a second endopposed to the first open end configured to be either closed or in fluidcommunication with a second duct assembly, and a plurality of orificesin the one or more air passages to distribute air out of the one or moreair passages; and a tray comprising opposed side walls defining aperimeter of the tray, and a raised region disposed within the perimeterof the tray wherein the side walls of the tray extend below the raisedregion to hold the raised region above the duct assembly, wherein theone or more air passages of the first end of the air box is in fluidcommunication with the one or more air passages of the duct assembly. 2.The system of claim 1, wherein the air passage of the ventilation systemhas a cross-section that decreases as the air passage passes from theintake filter through the fan and the air box to the one or more airpassages of the duct assembly.
 3. The system of claim 1, wherein theventilation system further comprises a component to amend air before itenters the duct assembly.
 4. The system of claim 3, wherein thecomponent to amend air comprises a filter, heater, cooler, dehumidifier,humidifier, carbon dioxide (CO₂) injector, ozone injector ultravioletlight, or combinations thereof.
 5. The system of claim 1, wherein thefirst and second ends of the air box comprise openings that are notperpendicular to each other.
 6. The system of claim 1, wherein the firstand second ends of the air box comprise openings that are parallel toeach other.
 7. The system of claim 1, wherein the duct assembly furthercomprises: one or more top panels; one or more bottom panels; a firstelongate side support member and a second elongate side support member,each of the first and second elongate side support members are parallelto the side walls of the tray and engaged to the one or more top panelsand the one or more bottom panels of the duct assembly; and one or moreelongate center support members parallel to the side walls of the trayand engaged with the one or more top panels and the one or more bottompanels of the duct assembly, wherein the first and second elongate sidesupport members, the one or more top panels, the one or more bottompanels, and the one or more center support members define one or moreair passages comprising ends proximate to the ends of the tray.
 8. Thesystem of claim 7, wherein the one or more top panels comprise thebottom surface of the raised region of the tray.
 9. The system of claim7, wherein the duct assembly further comprises: a plurality of holes inthe one or more top panels configured to be in fluid communication witha plurality of holes in the raised region of the tray to direct air fromthe duct assembly to above the tray; or a plurality of holes in the oneor more bottom panels configured to direct air from the duct assembly tobelow the duct assembly; or a plurality of holes in the one or more toppanels configured to be in fluid communication with a plurality of holesin raised region of the tray to direct air from the duct assembly toabove the tray and a plurality of holes in the one or more bottom panelsconfigured to direct air from the duct assembly to below the ductassembly.
 10. The system of claim 8, wherein the duct assembly comprisesa plurality of holes in the one or more top panels configured to be influid communication with the plurality of holes in the raised region ofthe tray to direct air from the duct assembly to above the tray.
 11. Thesystem of claim 8, wherein the duct assembly further comprises aplurality of holes in the one or more bottom panels configured to directair from the duct assembly to below the duct assembly.
 12. The system ofclaim 8, wherein the duct assembly comprises a plurality of holes in theone or more top panels configured to be in fluid communication withholes in the raised region of the tray such that air is directed fromthe duct assembly to above the tray, and a plurality of holes in the oneor more bottom panels such that air is directed from the duct assemblyto below the duct assembly.
 13. The system of claim 1, wherein theraised region of the tray comprises: a plurality of alternating parallelridges disposed between the side walls and a plurality of valleys formedbetween adjacent ridges of the plurality of ridges, wherein one or moreof the plurality of valleys are in fluid communication with a gutter;and one or more of a plurality of holes in one or more of the pluralityof ridges.
 14. The system of claim 12, wherein, the plurality ofalternating parallel ridges comprise top surfaces defining a level planefor supporting one or more individual growing containers for containinggrowth medium and plants, and the plurality of valleys slope downwardfrom a peak to a gutter proximate to the perimeter of the upper tray,the one or more of the plurality of valleys are in fluid communicationwith the gutter for channeling fluid collected into the gutter.
 15. Thesystem of claim 12, wherein a set of the plurality of alternatingparallel ridges comprises a central boss.
 16. The system of claim 12,wherein the gutter is configured to be in fluid communication with afluid drainage system.
 17. The system of claim 9, further comprising: aduct member disposed above the tray, the duct member comprising a hollowelongate member defining a lumen and a plurality of openings in thehollow elongate member, wherein the lumen and the plurality of openingsare in fluid communication with the plurality of holes in the raisedregion of the tray and the plurality of holes in the one or more toppanels of the duct assembly such that air is directed from the ductassembly to above the tray.
 18. The system of claim 16, wherein the ductmember disposed above the tray is disposed parallel to the ends of thetray.
 19. The system of claim 16, wherein the duct member disposed abovethe tray is disposed perpendicular to the ends of the tray.
 20. Thesystem of claim 1 comprising: a first duct assembly comprising one ormore air passages, a first end in fluid communication with theventilation system and a second end opposed to the first end open and influid communication with a first end of a second duct assemblycomprising one or more air passages, and a plurality of orifices in theone or more air passages of the first and second duct assembly todistribute air out of the one or more air passages; and a first tray anda second tray overlying the first duct assembly and the second ductassembly to provide an integrated system.
 21. The system of claim 1,wherein the duct assembly and the tray are configured to rest on a racksystem.
 22. A system for plant cultivation, comprising: a ventilationsystem comprising an air passage and an air box, the air passagecomprising a fan having an intake side and an outlet side, and the airbox comprising a first end and a second end, the first end of the airbox comprising one or more air passages and the second end of the airbox connected to the outlet side of the fan; a tray comprising opposedside walls defining a perimeter of the tray, and a raised regiondisposed within the perimeter of the tray wherein the side walls of thetray extend below the raised region to hold the raised region above theduct assembly, a duct assembly comprising one or more air passages, theduct assembly having a first end in fluid communication with theventilation system, a second end opposed to the first open endconfigured to be either closed or in fluid communication with a secondduct assembly, and a plurality of orifices in the one or more airpassages to distribute air out of the one or more air passages; whereinthe one or more air passages of the first end of the air box is in fluidcommunication with the one or more air passages of the duct assembly;wherein the duct assembly comprises one or more top panels; one or morebottom panels; a first elongate side support member and a secondelongate side support member, each configured parallel to the side wallsof the tray and engaged to the one or more top panels and the one ormore bottom panels wherein the first and second elongate side supportmembers each comprise a top section configured to support a bottomsurface of the raised region of the tray proximate to the sides of thetray and a shelf to engage a top panel of the duct assembly, and abottom section comprising a shelf extending toward the central supportmember configured to engage a bottom panel of the duct assembly; and acenter support member configured parallel to the side walls of the trayand engaged with the one or more top panels and the one or more bottompanels having a cross-section comprising a top section configured tosupport a bottom surface of the raised region of the tray, a middlesection comprising a bar, and a bottom section including a first shelfextending from a first side of the middle bar section, and a secondshelf extending from a second side of the middle bar section, whereinthe first and second side support members, the one or more top panels,the one or more bottom panels, and the center support member define oneor more air passages having ends proximate to the ends of the tray. 23.A system for plant cultivation, comprising: a duct assembly comprisingone or more air passages, the duct assembly having a first end in fluidcommunication with a ventilation system, a second end opposed to thefirst open end configured to be either closed or in fluid communicationwith a second duct assembly, and a plurality of orifices in the one ormore air passages to distribute air out of the one or more air passages;and a tray comprising opposed side walls defining a perimeter of thetray, and a raised region disposed within the perimeter of the traywherein the side walls of the tray extend below the raised region tohold the raised region above the duct assembly.
 24. The system of claim23, wherein the duct assembly further comprises: one or more top panels,wherein the one or more top panels comprise a bottom surface of theraised region of the tray. one or more bottom panels; a first elongateside support member and a second elongate side support member, each ofthe first and second elongate side support members are parallel to theside walls of the tray and engaged to the one or more top panels and theone or more bottom panels of the duct assembly; wherein the first andsecond elongate side support members, the one or more top panels, theone or more bottom panels, define one or more air passages comprisingends proximate to the ends of the tray.